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SERVICE STATION MANUAL
633929(IT)-633930(EN)-633931(FR)-633932(ES)-633937(ES)-633938(PT)-633941(NL)-633942(EL)
MP3 125
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SERVICE STATIONMANUAL
MP3 125
The descriptions and illustrations given in this publication are not binding. While the basic features asdescribed and illustrated in this manual remain unchanged, PIAGGIO - GILERA reserves the right, atany time and without being required to update this publication beforehand, to make any changes to
components, parts or accessory supplies, which it considers necessary to improve the product or whichare required for manufacturing or construction reasons.
Not all versions shown in this publication are available in all Countries. The availability of individualversions should be confirmed with the official Piaggio sales network.
" Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publicationin whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-SalesV.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
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SERVICE STATION MANUALMP3 125
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops ofPiaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggiovehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Anysignificant changes to vehicle characteristics or to specific repair operations will be communicated byupdates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipmentand tools are unavailable. It is therefore advisable to read the sections of this manual relating to specialtools, along with the special tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personalinjury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicleto prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of seriousdamage to the vehicle and sometimes even the invalidity of the guarantee.
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INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICALSYSTEM ELE SYS
ENGINEFROMVEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKINGSYSTEM BRAK SYS
COOLINGSYSTEM COOL SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME
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INDEX OF TOPICS
CHARACTERISTICS CHAR
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This section describes the general specifications of the vehicle.
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well-
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant waterand seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid open flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the
work surfaces except the tapered couplings before refitting.- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. Using unsuitable
coupling members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.
Characteristics MP3 125
CHAR - 2
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Vehicle identification
Chassis prefix (FULL OPTIONAL): ZAPM47301
Chassis prefix (BASE): ZAPM300
Engine prefix: M473M
Dimensions and mass
WEIGHTS AND DIMENSIONS
Specification Desc./Quantity
Dry weight (FULL OPTIONAL) 210 5 kg
Dry weight (BASE) 199 5 kg
Wheelbase 1490 mmHeight 1245 mm
Width (handlebar) 745 mm
Overall length 2130 mm
Track 420 mm
MP3 125 Characteristics
CHAR - 3
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Engine
DATA
Specification Desc./QuantityType single-cylinder, four-stroke
Timing system single overhead camshaft chain driven on the left-hand side, three-arm rocking levers set up with
threaded set screw
Bore x stroke 57 x 48.6 mm
Cubic capacity 124 cm
Compression ratio 11.5 - 12.5 : 1
Air filter sponge, impregnated with mixture (50% petrol and50% oil)
Starting system electric starter motor with freewheel
Lubrication with lobe pump (inside the crankcase) controlledby a chain and double filter: mesh and paper
Fuel supply Unleaded petrol; depression carburettor, electricpump or vacuum pump.
valve clearance intake: 0.10 mm - discharge: 0.15 mm
Engine idle speed 1,650100 rpm
Max. speed 100 km/h
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission With automatic expandable pulley variator with tor-que server, V belt, self-ventilating automatic cen-trifugal dry clutch, gear reduction unit and trans-
mission housing with forced air circulation cooling.
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil 1200 cm
Rear hub oil Capacity ~ 150 cmFuel tank capacity Tank capacity: ~12 l (approximate value)
Fuel reserve ~ 2.0 l (approximate value)
Cooling circuit Capacity: ~ 2.0 l
Electrical system
ELECTRICAL COMPONENTS
Specification Desc./Quantity
Ignition/advance Electronic, with inductive discharge and variableadvance with three-dimensional mapping
Spark plug NGK CR 8EB
Spark plug Champion RG 4 HC
Characteristics MP3 125
CHAR - 4
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Specification Desc./Quantity
Battery 12V-12Ah
Generator Three-phase alternating current
Frame and suspensions
FRAME AND SUSPENSIONS
Specification Desc./Quantity
Chassis Tubular and sheet steel.
Rear suspension Single arm with two double-acting hydraulic shockabsorbers and preloading adjustable to 4 posi-
tions.
Front suspension The tilt mechanism is composed of an articulatedparallelogram suspension with die-cast aluminiumcontrol arms and two side headstocks plus shock
absorbers with hydraulic locking system.
Brakes
BRAKES
Specification Desc./Quantity
Front brake 240 mm double disk with hydraulic control acti-vated by the handlebar right-hand lever.
Rear brake 240 mm disc brake with hydraulic control acti-vated by the handlebar left-side lever.
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Front wheel Alloy rims: 12" x 3.00"
Rear wheel Alloy rim: 12"x 3.50"
Front tyre 120/70-12", without inner tube
Rear tyre Without inner tube: 130/70-12" 62P
TYRE PRESSURE
Specification Desc./Quantity
Front tyre pressure (rider) Front tyre pressure (rider): 1.6 bar
Front tyre pressure (rider and passenger) Front tyre pressure (rider and passenger): 1.8 bar
Rear tyre pressure (rider) Rear tyre pressure (rider): 2 bar
Rear wheel pressure (rider and passenger): Rear tyre pressure (rider and passenger): 2.4 bar
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES
MP3 125 Characteristics
CHAR - 5
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Tightening Torques
STEERING
Name Torque in NmSteering lower ring nut (central headstock) 22 27 loosen by 90
Steering upper ring nut (central headstock) 27 33
Handlebar fixing screw 50 55
Fixing screws for handlebar control assembly U-bolts
7 10
FRAME
Name Torque in Nm
Engine arm bolt - frame arm 33 41
Swinging arm buffer nut 64 - 72
Engine-swinging arm bolt 55 61
Frame-swinging arm bolt 55 61Centre stand bolt 31 39
FRONT SUSPENSION
Name Torque in Nm
Shock absorber lower clamp 19 26
Upper shock absorber clamp 19 29
Front wheel fixing screws 19 24
Steering arm bolt nut 20 25
Tilt calliper fixing screws 20 25
Front wheel shaft 74 88
Arm coupling screws 45 50
Screws fixing arms to side headstocks 45 50Screws fixing arms to central headstock 45 50
Screws fixing the half-arm coupling flange 20 25
Fixing screws for tilt locking disc section 20 25
Side headstock upper ring nut 20 - 24
Side headstock lower ring nut 12 15
Screw fixing sliding stem to shock absorber 45 50
Clamp for sliding stem locking device 6.5 10.5
Fixing nuts for constant-velocity universal joints 18 20
Potentiometer to anti-tilting device clamp 8 10
Electric motor to anti-tilting device clamp 11 13
Clamp fixing pump bolt to anti-tilting device 11 13
Pump to anti-tilting device clamp 11 13Pressure switch to distribution frame 18 20
Sensor to tilt gripper clamp 2.5 2.9
Pipe terminals to fifth wheel check spring 7 11
Joint to anti-tilting device pump 20 25
Lower fitting for shock absorber sliding lockingclamp pipes
20 25
Upper fitting for shock absorber sliding lockingclamp pipes
20 25
REAR SUSPENSION
Name Torque in Nm
Upper shock absorber clamp 33 41
Shock absorber lower clamp 33 41
Characteristics MP3 125
CHAR - 6
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Name Torque in Nm
Shock absorber-crankcase attachment bracket 20 25
Rear wheel axle 104 126
Muffler arm clamping screws 27 30
FRONT BRAKE
Name Torque in Nm
Oil bleed screw 812
Disc tightening screw () 5 - 6
Brake fluid pump - hose fitting 16 20
Brake fluid pipe-calliper fitting 20 25
Screw tightening calliper to the support 20 25
Calliper upper pipe fitting 20 25
REAR BRAKE
Name Torque in Nm
Rear brake disc screws() 5 6.5Rear brake calliper-pipe fitting 20 25
Rigid / flexible pipe fitting 13 18
Rear brake pump-pipe fitting 16 20
Rear brake calliper fixing screws 20 25
REAR BRAKE
Product Description Specifications
() Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-strength threadlock
MUFFLER
Name Torque in Nm
Muffler heat guard fixing screw 4 5
Screw for fixing muffler to the support arm 20 25
Lambda probe clamp on exhaust manifold 40 50
Exhaust manifold-muffler joint clamp 12 13
Manifold - muffler diaphragm tightening clamp 16 18
LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 17
Oil filter on crankcase fitting 27 33
Engine oil drainage plug/mesh filter 24 30Oil filter 4 6
Oil pump cover screws 0.7 0.9
Screws fixing oil pump to the crankcase 5 - 6
Oil pump control crown screw 10 14
Oil pump cover plate screws 4 6
Oil sump screws 10 14
Minimum oil pressure sensor 12 14
ENGINE - CYLINDER HEAD
Name Torque in Nm
Manifold-silencer retaining bolt 15 20
Nut fixing muffler to cylinder head 16 18Camshaft retention plate screw 4 6
MP3 125 Characteristics
CHAR - 7
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Name Torque in Nm
Timing chain tensioner central screw 5 - 6
Timing chain tensioner support screw 11 13
Starter ground support screw 11 15
Timing chain tensioner slider screw 10 14
Inlet manifold screws 11 13
Tappet set screw lock nut 6 8
Starter ground screw 7 8.5
Head fixing side screws 11 12
Nuts fixing head to cylinder (*) 27 29
Tappet cover screws 6 7
Spark plug 12 14
ENGINE - TRANSMISSION
Name Torque in Nm
Rear hub cover screws 24 27
Driven pulley shaft nut 54 60Transmission cover screws 11 13
Drive pulley nut 75 83
Clutch unit nut on driven pulley 55 60
Belt support roller screw 11 13
ENGINE - FLYWHEEL
Name Torque in Nm
Pick-Up clamping screws 3 4
Stator assembly screws () 3 4
Flywheel cover fixing screws 5 - 6
Flywheel nut (250) 94 102
Screw fixing freewheel to flywheel 13 15
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Internal engine crankcase bulkhead (transmis-sion-side half shaft) screws
4 6
Engine-crankcase coupling screws 11 13
Starter motor screws 11 13
Crankcase timing system cover screws () 3.5 4.5
ENGINE - COOLING
Product Description Specifications() Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-strength threadlock
Overhaul data
Assembly clearances
Characteristics MP3 125
CHAR - 8
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Cylinder - piston assy.
ENGINE COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
Cylinder A 56.997 57.004 56.945 56.952 0.045 - 0.059
Cylinder B 57.004 57.011 56.952 56.959 0.045 - 0.059Piston C 57.011 57.018 56.959 56.966 0.045 - 0.059
Piston D 57.018 57.025 56.966 56.973 0.045 - 0.059
Cylinder 1st Over-size
A1 57.197 57.204 57.145 57.152 0.045 - 0.059
Cylinder 1st Over-size
B 1 57.204 57.211 57.152 57.159 0.045 - 0.059
Piston 1st Over-size
C 1 57.211 57.218 57.159 57.166 0.045 - 0.059
Piston 1st Over-size
D 1 57.218 57.225 57.166 57.173 0.045 - 0.059
Cylinder 2nd Over-size
A2 57.397 57.404 57.345 57.352 0.045 - 0.059
Cylinder 2nd Over-size
B 2 57.404 57.411 57.352 57.359 0.045 - 0.059
Piston 2nd Over-size
C 2 57.411 57.418 57.359 57.366 0.045 - 0.059
Piston 2nd Over-size
D 2 57.418 57.425 57.366 57.373 0.045 - 0.059
Cylinder 3rd Over-size
A 3 57.597 57.604 57.545 57.552 0.045 - 0.059
Cylinder 3rd Over-size
B 3 57.604 57.611 57.552 57.559 0.045 - 0.059
Piston 3rd Over-size
C 3 57.611 57.618 57.559 57.566 0.045 - 0.059
Piston 3rd Over-size
D 3 57.618 57.625 57.566 57.573 0.045 - 0.059
MP3 125 Characteristics
CHAR - 9
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Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000car.)
Indirizzo Immagine
Crankshaft Crankshaft to crankcaseaxial clearance
Crankshaft to crankcase axial clearance
CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE
Name Description Dimensions Initials Quantity
Half-shaft, trans-mission side
16.6 +0-0.05 A D = 0.20 - 0.50
Flywheel-side half-shaft
16.6 +0-0.05 B D = 0.20 - 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50Spacer tool 51.4 +0.05 E D = 0.20 - 0.50
Slot packing system
Characteristic
Compression ratio
Cr: 11.50 13:1
Characteristics MP3 125
CHAR - 10
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Measurement A to be taken, is a value of piston protrusion. It indicates by how much the plane formed
by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the
piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression
ratio) and vice versa.N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL-INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FORMEASUREMENT A TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION ANDON A RECTIFIED PLANE.
MODELSWITHFIBREHEADGASKET (1.1)
Name Measure A Thickness
Shimming 125 - Cylinder 67 -Head gasket 1.1 - Base gasket
0.4
2.20 2.45 0.4 0.05
Shimming 125 - Cylinder 67 -Head gasket 1.1 - Base gasket
0.6
2.45 2.70 0.6 0.05
Characteristic
Compression ratio
Cr: 11.50 13:1
MP3 125 Characteristics
CHAR - 11
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Measurement A to be taken, is a value of piston protrusion. It indicates by how much the plane formed
by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the
piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression
ratio) and vice versa.N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL-INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FORMEASUREMENT A TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION ANDON A RECTIFIED PLANE.
MODELSWITHMETALLICHEADGASKET (0.3)
Name Measure A Thickness
Shimming 125 - Cylinder 67.8 -Head gasket 0.3 - Base gasket
0.4
1.40 1.65 0.4 0.05
Shimming 125 - Cylinder 67.8 -Head gasket 0.3 - Base gasket
0.6
1.65 1.90 0.6 0.05
Products
RECOMMENDED PRODUCTS TABLE
Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds therequirements of API GL3 specifi-
cations
Characteristics MP3 125
CHAR - 12
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Product Description Specifications
AGIP CITY HI TEC 4T Oil to lubricate flexible transmis-sions (throttle control)
Oil for 4-stroke engines
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additivesfor increased adhesiveness
AGIP GP 330 Calcium complex soap-basedgrease with NLGI 2; ISO-L-
XBCIB2
Grease (brake control levers,throttle grip)
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3,JASO MA Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
SPECIAL AGIP PERMANENTfluid
coolant Monoethylene glycol-based anti-freeze fluid, CUNA NC 956-16
MP3 125 Characteristics
CHAR - 13
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Characteristics MP3 125
CHAR - 14
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INDEX OF TOPICS
TOOLING TOOL
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APPROPRIATE TOOL
Stores code Description
001330Y Tool for fitting steering seats
001467Y014 Pliers to extract 15-mm bear-ings
005095Y Engine support
002465Y Pliers for circlips
006029Y Punch for fitting fifth wheel seaton steering tube
020004Y Punch for removing fifth wheelsfrom headstock
020055Y Wrench for steering tube ring nut
Tooling MP3 125
TOOL - 2
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Stores code Description
020074Y Support base for checking crank-shaft alignment
020150Y Air heater support
020151Y Air heater
020193Y Oil pressure gauge
020262Y Crankcase splitting strip
020263Y Sheath for driven pulley fitting
MP3 125 Tooling
TOOL - 3
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Stores code Description
020306Y Punch for assembling valve sealrings
020329Y MityVac vacuum-operated pump
020330Y Stroboscopic light for timing con-trol
020331Y Digital multimeter
020332Y Digital rev counter
Tooling MP3 125
TOOL - 4
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Stores code Description
020333Y Single battery charger
020334Y Multiple battery charger
020335Y Magnetic support for dial gauge
020357Y 32 x 35 mm adaptor
020359Y 42x47-mm adaptor
020360Y Adaptor 52 x 55 mm
MP3 125 Tooling
TOOL - 5
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Stores code Description
020363Y 20 mm guide
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020382Y Valve cotters equipped with part012 removal tool
020382Y011 adapter for valve removal tool
Tooling MP3 125
TOOL - 6
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Stores code Description
020393Y Piston fitting band
020412Y 15 mm guide
020423Y driven pulley lock wrench
020424Y Driven pulley roller casing fittingpunch
020426Y Piston fitting fork
MP3 125 Tooling
TOOL - 7
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Stores code Description
020431Y Valve oil seal extractor
020434Y Oil pressure control fitting
020444Y Tool for fitting/ removing the driv-en pulley clutch
020456Y 24 mm adaptor
020477Y Adaptor 37 mm
020483Y 30 mm guide
Tooling MP3 125
TOOL - 8
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Stores code Description
020489Y Hub cover support stud bolt set
020428Y Piston position check support
020621Y HV cable extraction adaptor
001467Y035 Belle for OD 47-mm bearings
020626Y Driving pulley lock wrench
001467Y013 Pliers to extract 15-mm bear-ings
MP3 125 Tooling
TOOL - 9
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Stores code Description
020627Y Flywheel lock wrench
020467Y Flywheel extractor
020454Y Tool for fitting piston pin stops(200 - 250)
020622Y Transmission-side oil guardpunch
020480Y Petrol pressure check set
020244Y 15 mm diameter punch
Tooling MP3 125
TOOL - 10
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Stores code Description
020115Y 18 punch
020271Y Tool for removing-fitting silentbloc
001467Y017 Driver for OD 36 mm bearings
020234y extractor
020441Y 26 x 28 mm adaptor
020362Y 12 mm guide
020358Y 37x40-mm adaptor
MP3 125 Tooling
TOOL - 11
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Stores code Description
001467Y002 Driver for OD 73 mm bearing
020641Y EFI Technology software up-grade
020469Y Reprogramming kit for scooterdiagnosis tester
020639Y Tilt locking control unit software
020481Y Control unit interface wiring
Tooling MP3 125
TOOL - 12
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Stores code Description
020481Y004 Parking control unit interface wir-ing
020460Y Scooter diagnosis and tester
MP3 125 Tooling
TOOL - 13
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Tooling MP3 125
TOOL - 14
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INDEX OF TOPICS
MAINTENANCE MAIN
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Follow these steps to reset the service icons:
1. With the key set to OFF, hold down the
"SET" button and turn the key to ON : the
"BELT" and "SERVICE" icons start flashing.
2. Push the "CLOCK" button for less than 1
second and the icons are displayed sequen-
tially. The icon selected remains ON and the
other is no longer displayed.
3. Press the "CLOCK" button again for more
than 3 seconds to reset the relative mainte-
nance step and the icon is no longer dis-
played.
Maintenance chart
EVERY 2 YEARS
75
Action
Coolant - change
Brake fluid - change
secondary air filter - cleaning
EVERY 3.000 KM
10'
Action
Engine oil - level check/ top-up
AFTER 1,000 KM
90'
Action
Engine oil - replacement
Hub oil - change
Engine oil - changeIdle speed (*) - adjustment
Throttle lever - adjustment
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Tilt locking gripper control cable - adjustment
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in Idle speed adjustment section
Maintenance MP3 125
MAIN - 2
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AFTER 6.000 KM
130'
Action
Hub oil level - checkSpark plug/ electrode gap - check
Air filter - clean
Sliding blocks / variable speed rollers - check
Driving belt - check
Coolant level - check
Brake pads - check condition and wear
Brake fluid level - check
Tilt locking gripper control cable - adjustment
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
Engine oil - changeOil filter -Replacement
Valve clearance - check
AFTER 12,000 KM AND AFTER 60,000 KM
140'
Action
Engine oil - replacement
Hub oil level - check
Spark plug / electrode gap - check / replacement
Air filter - clean
Engine oil - change
Idle speed (*) - adjustment
Sliding block / variable speed rollers - change
Throttle lever - adjustment
Coolant level - check
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Tilt locking gripper control cable - adjustment
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
Vehicle and brake test - road test
Driving Belt - replacement
(*) See instructions in Idle speed adjustment section
AFTER 18,000 KM AND AFTER 54,000 KM
110'
Action
Hub oil level - check
Spark plug/ electrode gap - checkAir filter - clean
MP3 125 Maintenance
MAIN - 3
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Action
Sliding blocks / variable speed rollers - check
Driving belt - check
Coolant level - check
Radiator - external cleaning/ check
Brake pads - check condition and wear
Brake fluid level - check
Tilt locking gripper control cable - adjustment
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
Engine oil - change
Oil filter -Replacement
Valve clearance - Check
AFTER 24,000 KM AND AFTER 48,000 KM
170'Action
Engine oil - replacement
Hub oil - change
Spark plug / electrode gap - check / replacement
Air filter - clean
Engine oil - change
Idle speed (*) - adjustment
Sliding block / variable speed rollers - change
Throttle lever - adjustment
Coolant level - check
Steering - adjustment
Brake control levers - greasingBrake pads - check condition and wear
Brake fluid level - check
Tilt locking gripper control cable - adjustment
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
Vehicle and brake test - road test
Driving Belt - replacement
(*) See instructions in Idle speed adjustment section
AFTER 30,000 KM, AFTER 42,000 KM AND AFTER 66,000 KM
100'
Action
Hub oil level - check
Spark plug/ electrode gap - check
Air filter - clean
Sliding blocks / variable speed rollers - check
Driving belt - check
Coolant level - check
Brake pads - check condition and wear
Brake fluid level - check
Tilt locking gripper control cable - adjustment
Maintenance MP3 125
MAIN - 4
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Action
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
Engine oil - change
Oil filter -Replacement
AFTER 36.000 KM
260'
Action
Engine oil - replacement
Hub oil level - check
Spark plug / electrode gap - check / replacement
Air filter - clean
Engine oil - change
Valve clearance - Check
Idle speed (*) - adjustmentSliding block / variable speed rollers - change
Throttle lever - adjustment
Driving belt - replacement
Coolant level - check
Radiator - external cleaning/ check
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid hoses - replacement
Brake fluid level - check
Tilt locking gripper control cable - adjustment
Transmission elements - lubricationSafety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in Idle speed adjustment section
AFTER 72.000 KM
280'
Action
Engine oil - replacement
Hub oil - change
Spark plug / electrode gap - check / replacement
Air filter - clean
Engine oil - change
Valve clearance - Check
Idle speed (*) - adjustment
Sliding block / variable speed rollers - change
Throttle lever - adjustment
Driving belt - replacement
Coolant level - check
Radiator - external cleaning/ check
Steering - adjustment
Brake control levers - greasing
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Action
Brake pads - check condition and wear
Brake fluid hoses - replacement
Brake fluid level - check
Tilt locking gripper control cable - adjustment
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in Idle speed adjustment section
Carburettor
- Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with
compressed air to ensure adequate cleaning.
- Check carefully that the parts are in good condition.
- The throttle valve should move freely in the chamber. Replace it in case of excessive clearance due
to wear.
- If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it
is new), replace the carburettor.
- It is advisable to replace the gaskets at every refit
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS
Checking the spark advance
The ignition advance is determined electronically
on the basis of parameters known by the control
unit. For this reason it is not possible to declare the
reference values based on the engine rpm. The
ignition timing value is detectable any time using
the diagnostic tester. It is possible to check wheth-
er the ignition advance determined by the system
does in fact correspond with the value actually ac-
tivated on the engine, by means of the strobo-
scopic light.
Proceed as follows:
- Remove the spark plug.
- Remove the transmission crankcase.
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- Rotate the driving pulley fan until the reference
marks between the flywheel and flywheel cover
coincide as shown in the photograph.
- Bring the reference mark onto the transmission
side between the fan and the transmission cover
as shown in the photograph.
- Refit the spark plug.
- Refit the plastic cap on the flywheel cover.
- Adjust the spark gap to the contact position (no
reference mark visible) and install it on engine be-
tween the spark plug and spark plug cap
- Connect the induction calliper on the spark gapcable respecting the proper polarity (the arrow on
the calliper must be pointing at the spark plug).
- Connect the diagnostic tester.
- Start the engine.
- Select the parameter function in this menu.
- Select the stroboscopic light command in the tra-
ditional four-stroke engine position (1 spark 2
revs).
- Check that the real values of rpm and ignition
advance match those measured using the diag-
nostic tester.
If the values do not correspond, check:
- distribution timing
- revolution-timing sensor
- Injection control unit
Specific tooling
020460YScooter diagnosis and tester
020330YStroboscopic light for timing control
020621YHV cable extraction adaptor
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Spark plug
To service the spark plug the engine must be cold,
proceed as follows:
- Undo the knob located inside the rear case and
remove the saddle.
- Remove the spark plug cap.
- Use the supplied spanner (with retaining rubber
ring) to remove the spark plug.
- Disconnect and remove the spark plug cable.
- Examine it carefully and replace it if the insulator
is chipped or cracked.
- Measure electrode gap with a thickness gauge
and, if necessary, adjust the gap by carefully bend-
ing the outer electrode forward or away.
- Make sure the sealing washer is in good condi-
tion.
- Fit the spark plug, screw it manually and lock it
to the prescribed torque with a spark plug spanner.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHENTHE MOTOR IS COLD. THE SPARK PLUGMUST BE REPLACED EVERY 12,000 KM. THEUSE OF NON CONFORMING IGNITION CON-TROL UNITS OR SPARK PLUGS OTHER THANTHOSE PRESCRIBED CAN SERIOUSLY DAM-AGE THE ENGINE.
Characteristic
Electrode gap
0.7-0.8 mm
Electric characteristic
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Spark plug
NGK CR 8EB
Locking torques (N*m)
Spark plug12 14
Hub oil
Make sure that there is oil in the rear hub (amount
of oil contained ~ 150 cm). To check the rear hub
oil level, proceed as follows:
1) Park the scooter on level ground and place it on
the centre stand.
2) Unscrew the dipstick "A", dry it with a clean rag
and then reinsert it, screwing it tightly into
place;
3) Remove the dipstick and check that the oil level
is above the first notch from the bottom.
4) Screw the dipstick back in, checking that it is
locked in place.
N.B.
THE REFERENCE MARKS ON THE HUB OIL
LEVEL DIPSTICK, EXCEPT FOR THE ONE IN-DICATING THE "MAX" LEVEL, REFER TO OTH-ER MODELS BY THE MANUFACTURER ANDHAVE NO SPECIFIC FUNCTION FOR THISMODEL.
CAUTION
RIDING THE VEHICLE WITH INSUFFICIENTHUB LUBRICATION OR WITH CONTAMINA-TED OR IMPROPER LUBRICANTS ACCELER-ATES THE WEAR AND TEAR OF THE MOVINGPARTS AND CAN CAUSE SERIOUS DAMAGE.
CAUTION
USED OILS CONTAIN SUBSTANCES HARM-FUL TO THE ENVIRONMENT. FOR OIL RE-PLACEMENT, CONTACT AN AUTHORISEDSERVICE CENTRE, WHICH IS EQUIPPED TODISPOSE OF USED OILS IN AN ENVIRONMEN-TALLY FRIENDLY AND LEGAL WAY.
CAUTION
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UPON REPLACING HUB OIL, AVOID THE OILCOMING INTO CONTACT WITH THE REARBRAKE DISC.
Recommended products
AGIP ROTRA 80W-90Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Check
- Rest the vehicle on its centre stand on an even surface. - Unscrew the oil dipstick, dry it with a clean
cloth and reinsert it, screwing it in thoroughly.- Take out the dipstick and check that the oil level reaches
the 2nd notch from the bottom.- Screw the dipstick back into place completely.
Recommended products
AGIP ROTRA 80W-90Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Locking torques (N*m)
Hub oil drainage plug15 17
Replacement
-Remove the oil cap A.
- Unscrew the oil drainage cap "B" and drain out
all the oil.
- Screw on the drainage plug and fill up the hub
with oil (about 150 cc)
Air filter
Remove the air cleaner cap after undoing the re-
tainer screws, then extract the filter.
- Wash with water and neutral soap.
-Dry with a clean cloth and short blasts of com-
pressed air.
- Soak with a mixture of 50% petrol and 50% SE-
LENIA AIR FILTER OIL.
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-Drip dry the filter and then squeeze it between the
hands without wringing.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIRFILTER, THIS WOULD RESULT IN AN EXCES-SIVE WEAR OF THE PISTON AND CYLINDER.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THEAIR FILTER MUST BE CLEANED MORE OFTENTHAN SHOWN IN THE SCHEDULED MAINTE-NANCE CHART.
Engine oil
Replacement
The engine oil and cartridge filter, "C", must be re-
placed after the first km, and every 6.000 km there-
after, by an Authorised Piaggio Service Cen-
tre. The engine should be emptied by draining the
oil from the drainage cap "B" of the gauze filter on
the flywheel side. In order to facilitate the oil drain-
age, loosen the cap/dipstick. Since a certain quan-
tity of oil remains in the circuit still, the top-up
should be carried out with around 600 650 cm
of oil from cap "A". Then start up the scooter, leave
it running for a few minutes and switch it off: after
five minutes, check the level and if necessary top
up without exceeding the MAX. level. The car-
tridge filter must be replaced at every oil change.
For top up and change, use new oil of the recom-
mended type.
WARNING
RUNNING THE ENGINE WITH INSUFFICIENTLUBRICATION OR WITH INADEQUATE LUBRI-CANTS ACCELERATES THE WEAR AND TEAROF THE MOVING PARTS AND CAN CAUSE IR-RETRIEVABLE DAMAGE.
WARNING
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EXCESSIVE OIL LEVEL AT TOP-UPS CANLEAD TO SCALE FORMATION AND VEHICLEMALFUNCTIONING.
CAUTION
USED OILS CONTAIN SUBSTANCES HARM-FUL TO THE ENVIRONMENT. FOR OIL RE-PLACEMENT, CONTACT AN AUTHORISEDPIAGGIO SERVICE CENTRE, AS THEY AREEQUIPPED TO DISPOSE OF SPENT OILS IN ANENVIRONMENTALLY FRIENDLY AND LEGALWAY.
CAUTION
USING OILS OTHER THAN THOSE RECOM-MENDED CAN SHORTEN THE LIFE OF THEENGINE.
Recommended products
AGIP CITY HI TEC 4TEngine oil
SAE 5W-40, API SL, ACEA A3, JASO MA Syn-
thetic oil
Check
Every time the scooter is used, a visual check
should be made on the level of the engine oil when
the engine is cold. The oil level should be some-
where between the MAX and MIN index marks on
the level bar; the check must be made with the
scooter upright, resting on the centre stand. If the
check is carried out after the vehicle has been
used, and therefore with a hot engine, the level line
will be lower; in order to carry out a correct check
it is necessary to wait at least 10 minutes after the
engine has been stopped, so as to get the correct
level.
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Checking the ignition timing
-Remove the 4 fixing screws and move away from
the engine the flywheel cover fitted with a water
pump and cooling manifolds.
-Rotate the flywheel until the reference matches
the crankcase operation end as shown in the figure
(TDC). Make sure that the 4V reference point on
the camshaft control pulley is aligned with the ref-
erence point on the head as shown in the second
figure. If the reference mark is opposite the indi-
cator on the head, make the crankshaft turn once
more.
-The TDC reference mark is repeated also be-
tween the flywheel cooling fan and the flywheel
cover.
To use this reference mark, remove the spark plug
and turn the engine in the opposite direction to the
normal direction using a calliper spanner applied
to the camshaft command pulley casing.
N.B.TIME THE TIMING SYSTEM UNIT IF IT IS NOTIN PHASE.
Checking the valve clearance
-To check valve clearance, centre the reference
marks of the timing system
- Use a thickness gauge to check that the clear-
ance between the valve and the register corre-
sponds with the indicated values. When the valve
clearance values, intake and drainage respective-
ly, are different from the ones indicated below,
adjust them by loosening the lock nut and operate
on the register with a screwdriver as shown in the
figure.
Intake: 0.10 mm (when cold)
Discharge: 0.15 mm (when cold)
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Headlight adjustment
Proceed as follows:
1. Position the unloaded vehicle, in running order
and with the tyres inflated to the prescribed pres-
sure, on a flat surface 10 m away from a half-lit
white screen; ensure that the longitudinal axis of
the vehicle is perpendicular to the screen;
2. Remove the headlight assembly central cover
3. Turn on the headlight and check that the limit of
the projected light beam is not over 9/10 or below
7/10 of the distance from the ground to the centre
of the vehicle headlight;
4. Otherwise, adjust the headlight with the
screwsA indicated in the figure
N.B.
THE ABOVE PROCEDURE COMPLIES WITHTHE EUROPEAN STANDARDS REGARDINGMAXIMUM AND MINIMUM HEIGHT OF LIGHTBEAMS. REFER TO THE STATUTORY REGU-LATIONS IN FORCE IN EVERY COUNTRYWHERE THE vehicle IS USED.
SAS filters inspection and cleaning
Insert the filter into its housing.
Fit the valve support with the 3 screws
Insert the rubber spacer on the valve and proceed
with the assembly on the support.
Fix the support with the 2 screws.
Fit the pre-filter and position it matching the 2 ref-
erences shown in the figure.Fit the sealing gasket.
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Align the drive with the reference on the crankcase
cover.
Place the flywheel in the TDC position and align
the references as shown in the figure.
Check the correct fitting of the 2 reference dowels
and fit the engine cover.
Be careful to properly fit the flywheel connector to
the relative supplements.
Secure the rotor cover by using a new gasket with
the 4 screws.
Connect the flywheel connector and the valve con-
trol vacuum-operated pipe.Fit the coupling to the valve and position it as
shown in the figure.
Lock the upper clamp.
Fix the metal tube to the head using the gasket and
the 2 screws.
Lock the lower clamp connecting manifold / pipe.
Locking torques (N*m)
Stator assembly screws ()3 4
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Undo the 3 fixing screws "A", remove the secon-
dary air filter cover and then take out the filtering
element "B".- Wash with water and neutral soap.
-Dry with a clean cloth and short blasts of com-
pressed air.
Remove the flywheel cover by operating on its
clamps and remove the primary filtering element.
- Wash with water and neutral soap.
-Dry with a clean cloth and short blasts of com-
pressed air.
Check that the filter casing is clean paying special
attention to "A" and "B" passages
CAUTION
NEVER RUN THE ENGINE WITHOUT THE SEC-ONDARY AIR FILTER
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THEAIR FILTER MUST BE CLEANED MORE OFTENTHAN SHOWN IN THE SCHEDULED MAINTE-NANCE CHART.
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INDEX OF TOPICS
TROUBLESHOOTING TROUBL
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This section makes it possible to find what solutions to apply when troubleshooting.
For each breakdown, a list of the possible causes and respective interventions is given.
Engine
Poor performance
POORPERFORMANCE
Possible Cause Operation
The carburettor is dirty; fuel pump or vacuum valvedamaged
Remove, wash with solvent and dry with com-pressed air or replace
Excess of encrustations in the combustion cham-ber
Descale the cylinder, the piston, the head and thevalves
Incorrect timing or worn timing system elements Time the system again or replace the worn partsMuffler obstructed Replace
Air filter blocked or dirty. Dismantle the sponge, wash with water and sham-poo, then soak it in a mixture of 50% petrol and50% of specific oil (Selenia Air Filter Oil), then
hand dry without squeezing, allow to drip dry andthen reassemble.
Automatic starter failure Check: mechanical movement, electric connec-tion and fuel supply, replace if required.
Oil level exceeds maximum Check for causes and fill to reach the correct level
Lack of compression: parts, cylinder and valvesworn
Replace the worn parts
Transmission belt worn ReplaceInefficient automatic transmission Check the rollers and the pulley movement, re-
place the damaged parts and lubricate the drivenpulley moveable guide with Montblanc Molybde-
num Grease
Clutch slipping Check the clutch system and/or the bell and re-place if necessary
Overheated valves Remove the head and the valves, grind or replacethe valves
Wrong valve adjustment Adjust the valve clearance properly
Valve seat distorted Replace the head assembly
Air filter dirty Dismantle the sponge, wash with water and sham-
poo, then soak it in a mixture of 50% petrol and50% of specific oil (Selenia Air Filter Oil), then
hand dry without squeezing, allow to drip dry andthen reassemble.
Defective floating valve Check the proper sliding of the float and the func-tioning of the valve
Starting difficulties
DIFFICULT STARTING
Possible Cause Operation
Altered fuel characteristics Drain off the fuel no longer up to standard; then,refill
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Possible Cause Operation
Rpm too low at start-up or engine and start-upsystem damaged
Check the starter motor, the system and the torquelimiter
Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clear-ance
Engine flooded Try starting-up with the throttle fully open. If theengine fails to start, remove the spark plug, dry itand before refitting, make the motor turn so as toexpel the fuel excess taking care to connect the
cap to the spark plug, and this in turn to the ground.If the fuel tank is empty, refuel and start up.
Automatic starter failure Check: mechanical movement, electric connec-tion and fuel supply, replace if required.
Air filter blocked or dirty. Dismantle the sponge, wash with water and sham-poo, then soak it in a mixture of 50% petrol and50% of specific oil (Selenia Air Filter Oil), then
hand dry without squeezing, allow to drip dry and
then reassemble.Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit
components
The carburettor is dirty; fuel pump or vacuum valvedamaged
Remove, wash with solvent and dry with com-pressed air or replace
Flat battery Check the charge of the battery, if there are anysulphur marks, replace and use the new batteryfollowing the instructions shown in the chapter
Intake coupling cracked or clamps incorrectlytightened
Replace the intake coupling and check the clampsare tightened
Defective floating valve Check the proper sliding of the float and the func-tioning of the valve
Carburettor nozzles clogged Dismantle, wash with solvent and dry with com-pressed air
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST
Possible Cause Operation
Worn valve guides Check and replace the head unit if required
Worn valve oil guard Replace the valve oil guard
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the cou-pling seal
Worn or broken piston rings or piston rings thathave not been fitted properly
Replace the piston cylinder unit or just the pistonrings
Insufficient lubrication pressure
POOR LUBRICATION PRESSURE
Possible Cause Operation
By-Pass remains open Check the By-Pass and replace if required. Care-fully clean the By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump
componentsOil filter too dirty Replace the cartridge filter
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Possible Cause Operation
Oil level too low Restore the level using the recommended oil type(Selenia HI Scooter 4 Tech)
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE
Possible Cause Operation
Faulty fuel supply Check or replace the pump and the vacuum valve,check the vacuum intake and the pipe sealing
Incorrect float level Restore the level in the tank by bending on the floatthe thrusting reed of the petrol inlet rod so as tohave the float parallel to the tank level with the
carburettor inverted.
Water in the carburettor Empty the tank through the appropriate bleed nip-
ple.Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with com-
pressed air
Engine tends to cut-off at idle
ENGINE STOP IDLING
Possible Cause Operation
Incorrect timing Time the system and check the timing systemcomponents
Cut off device failure Check that the following parts work properly:valve; diaphragm; spring; and that the air calibra-tion elements are clean; check if the sponge filter
is clean too
Incorrect idle adjustment Adjust using the rpm indicator
Pressure too low at the end of compression Check the thermal group seals and replace worncomponents
Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuitcomponents
The starter remains on Check: electric wiring, circuit not interrupted, me-chanical movement and power supply; replace if
necessary
Minimum nozzle dirty Wash the nozzle with solvent and dry with com-
pressed air
Excessive exhaust noise
EXCESSIVEEXHAUSTNOISE
Possible Cause Operation
Secondary air device cut-off valve not working Replace the secondary air device
Depression intake pipe of the secondary air devicedisconnected or dented
Replace the pipe
Reed valve of the secondary air device does not
close correctly and wears out the rubber couplingbetween the device and the head pipe
Replace the device and the coupling
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High fuel consumption
HIGH FUEL CONSUMPTIONPossible Cause OperationFloat level Restore the level in the tank by bending on the float
the thrusting reed of the petrol inlet rod so as tohave the float parallel to the tank level with the
carburettor inverted.
Loose nozzles Check the maximum and minimum nozzles areadequately fixed in their fittings
Fuel pump failure Check that there is no fuel in the low-pressure duct
Starter inefficient Check: electric wiring, circuit continuity, mechani-cal sliding and power supply
Air filter blocked or dirty. Dismantle the sponge, wash with water and sham-
poo, then soak it in a mixture of 50% petrol and50% of specific oil (Selenia Air Filter Oil), thenhand dry without squeezing, allow to drip dry and
then reassemble.
SAS malfunctions
ANOMALIESINTHESECONDARYAIRDEVICE
Possible Cause Operation
Secondary air device cut-off valve not working Replace the secondary air device
Depression intake pipe of the secondary air device
disconnected or dented
Replace the pipe
Reed valve of the secondary air device does notclose correctly and wears out the rubber coupling
between the device and the head pipe
Replace the device and the coupling
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGEPossible Cause Operation
Faulty clutch Check that there is no grease on the masses.Check that the clutch mass contact surface withthe casing is mainly in the centre with equivalentcharacteristics on the three masses. Check that
the clutch casing is not scored or worn in an anom-alous way
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Insufficient braking
INSUFFICIENTBRAKING
Possible Cause OperationInefficient braking system Check the pad wear (1.5 min). Check that thebrake discs are not worn, scored or warped. Checkthe correct level of fluid in the pumps and replacebrake fluid if necessary. Check there is no air in
the circuits; if necessary, bleed the air. Check thatthe front brake calliper moves in axis with the disc.
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pumpseals, replace
Brakes overheating
BRAKES OVERHEATING
Possible Cause Operation
Rubber gaskets swollen or stuck Replace gaskets.
Compensation holes on the pump clogged Clean carefully and blast with compressed air
Brake disc slack or distorted Check the brake disc screws are locked; use a dialgauge and a wheel mounted on the vehicle to
measure the axial shift of the disc.
Defective piston sliding Check calliper and replace any damaged part.
Electrical system
Battery
BATTERY
Possible Cause Operation
Battery This is the device in the system that requires themost frequent attention and the most thorough
maintenance. If the vehicle is not used for sometime (1 month or more) the battery needs to be re-charged periodically. The battery runs down com-
pletely in the course of 3 months. If the battery isfitted on a motorcycle, be careful not to invert theconnections, keeping in mind that the black groundwire is connected to the negative terminal while the
red wire is connected to the terminal marked+.
Turn signal lights malfunction
TURN INDICATOR NOT WORKING
Possible Cause Operation
Electronic ignition device failure With the key switch set to "ON" jump the contacts
1 (Blue - Black) and 5 (Red/Blue) on the controlunit connector. If by operating the turn indicator
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Possible Cause Operation
control the lights are not steadily on, replace thecontrol unit; otherwise, check the cable harness
and the switch.
Steering and suspensions
Rear wheel
REAR WHEEL ROTATES WITH ENGINE AT IDLE
Possible Cause Operation
Idling rpms too high Adjust the engine idle speed and the CO%, if nec-essary.
Clutch fault Check the springs / clutch masses
Controls
STEERING CONTROLS AND SUSPENSIONS
Possible Cause Operation
Torque not conforming Check the tightening of the top and bottom ringnuts. If irregularities continue in turning the steer-
ing even after making the above adjustments,check the seats in which the ball bearings rotate:if they are recessed or if the balls are squashed,
replace them.Steering hardening Check the tightening of the top and bottom ringnuts. If irregularities continue in turning the steer-
ing even after making the above adjustments,check the seats in which the ball bearings rotate:if they are recessed or if the balls are squashed,
replace them.
Malfunctions in the suspension system If the front suspension is noisy, check: the efficien-cy of the front shock absorbers; the condition ofthe ball bearings and relevant lock-nuts, the limitswitch rubber buffers and the movement bushings.In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber
disk in the attachment to the hub and the steeringtube.
Seal fault or breakage Replace the shock absorber Check the conditionof wear of the steering covers and the adjust-
ments.
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INDEX OF TOPICS
ELECTRICALSYSTEM ELE SYS
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KEY
1. Electronic ignition device
2. Immobilizer aerial
3. Throttle body position
4. Magneto flywheel Pick-up
5. CDI temperature sensor
6. Diagnostics socket
7. Engine stop switch
8. Voltage regulator
9. Main fuses
10. Battery
11. Starter motor
12. Start up remote control switch
13. Starter button
14 Secondary fuses
15. Stop button on rear brake
16. Stop button on front brake
17. Thermoswitch
18. Key switch
19. Radiator electric fan
Electrical system MP3 125
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20. Turn signal switch
21. Saddle opening receiver
1. Aerial
2. Actuator 1
3. Reset
4. +Battery
6. Key
7. Ground
11. Channel 1/3 selection
12. Alarm code out
22. Saddle opening actuator
23. Reset24. Hazard button
25. Wiring for Tom-Tom
26. Hazard and turn indicator control device
1. Hazard button
2. Left switch
3. Right switch
4. Left turn indicator
5. Right turn indicator
6. Ground
7. Key
8. +Battery
27. Wiring for antitheft device
28. Helmet compartment internal light
29. Rear left turn indicator
A. Left turn indicator bulbs
B. Stop light bulb
C. Tail light bulb
30. Licence plate lamp
31. Rear right turn indicator
A. Tail light bulb
B. Stop light bulb
C. Right turn indicator bulbs
32. Front left turn indicator
33. Headlight assembly
A. Tail light bulbs
B. Low-beam bulb
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C. High-beam bulb
34. Front right turn indicator
35. Horn button
36. Remote control headlight
37. Light switch
38. Helmet compartment light switch
39. Helmet compartment light switch
40. Instrument panel coolant temperature sensor
41. Mode button
42. Locking/unlocking switch
43. Horn remote control
44. Pressure sensor45. Horn
46. Geared motor
47. Brake calliper sensor
48. Parking electronic control unit
49. Right wheel revolution sensor
50. Left wheel revolution sensor
51. Potentiometer
52. Rider presence sensor
53. Oil pressure sensor
54. External temperature sensor
55. Parking brake button
56. Instrument panel
57. Fuel level transmitter
58. Electric pump control device (for scooters with electric pump only)
1. +Key
3. Pump ground connection
4. +Pump
5. Ground
6. Engine revs
59. Fuel pump (for scooters with electric pump only)
60. Starter
61. Spark plug
62. HV coil
KEY
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Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:
Red Ve: Green Vi: Purple
Conceptual diagrams
Ignition
KEY
1. Electronic ignition device
2. Immobilizer aerial
9. Main fuses
10. Battery
18. Key switch
61. Spark plug
62. HV coil
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Battery recharge and starting
KEY
1. Electronic ignition device
4. Magneto flywheel Pick-up
7. Engine stop switch
8. Voltage regulator
9. Main fuses
10. Battery
11. Starter motor
12. Start up remote control switch13. Starter button
14. Secondary fuses
15. Stop button on rear brake
16. Stop button on front brake
18. Key switch
29. Rear left turn indicator
A. Left turn indicator bulbs
B. Stop light bulb
C. Tail light bulb
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31. Rear right turn indicator
A. Tail light bulb
B. Stop light bulb
C. Right turn indicator bulbs
60. Starter
Level indicators and enable signals section
KEY
1. Electronic ignition device
2. Immobilizer aerial
3. Throttle body position
5. CDI Temperature sensor
7. Engine stop switch
9. Main fuses
10. Battery
14. Secondary fuses
18. Key switch
40. Instrument panel cooling liquid temperature sensor
47. Brake calliper sensor
48. Parking electronic control unit
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49. Right wheel revolution sensor
50. Left wheel revolution sensor
51. Potentiometer
52. Rider presence sensor
53. Oil pressure sensor
54. External temperature sensor
56. Instrument panel
57. Fuel level transmitter
Devices and accessories
KEY
1. Electronic ignition device
6. Diagnostics socket
7. Engine stop switch
9. Main fuses
10. Battery
14. Secondary fuses
17. Thermoswitch
18. Key switch
19. Radiator electric fan
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21. Saddle opening receiver
1. Aerial
2. Actuator 1
3. Reset
4. +Battery
6. Key
7. Ground
11. Channel 1/3 selection
12. Alarm code out
22. Saddle opening actuator
23. Reset
25. Wiring for Tom-Tom27. Wiring for antitheft device
28. Helmet compartment internal light
35. Horn button
38. Helmet compartment light switch
39. Helmet compartment light switch
41. Mode button
42. Locking/unlocking switch
43. Horn remote control
44. Pressure sensor
45. Horn
46. Geared motor
48. Parking electronic control unit
55. Parking brake button
56. Instrument panel
58. Electric pump control device (for scooters with electric pump only)
1. +Key
3. Pump ground connection
4. +Pump
5. Ground
6. Engine revs
59. Fuel pump (for scooters with electric pump only)
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Lights and turn indicators
KEY
7. Engine stop switch
9. Main fuses
10. Battery
14. Secondary fuses
18. Key switch
20. Turn signal switch
24. Hazard button
26. Hazard and turn signal control device1. Hazard button
2. Left switch
3. Right switch
4. Left turn indicator
5. Right turn indicator
6. Ground
7. Key
8. +Battery
29. Rear left turn indicator
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A. Left turn indicator bulbs
B. Stop light bulb
C. Tail light bulb
30. Licence plate lamp
31. Rear right turn indicator
A. Tail light bulb
B. Stop light bulb
C. Right turn indicator bulbs
32. Front left turn indicator
33. Headlight assembly
A. Tail light bulbs
B. Low-beam bulbC. High-beam bulb
34. Front right turn indicator
36. Remote control headlight
37. Light switch
48. Parking electronic control unit
56. Instrument panel
Checks and inspections
This section is devoted to the checks on the electrical system components.
Immobiliser
The electric ignition system is fed with direct cur-
rent and is protected by an anti-theft immobilizer
integrated to the control unit.
The ignition system consists of:
- electronic control unit
- immobilizer aerial
- master and service keys with built-in transponder
- H.V. coil
- diagnosis led
The diagnosis led also works as a blinking light to
deter theft. This function is activated every time the
key switch is turned to "OFF" and it remains active
48 hours so as not to damage the battery charging
process.
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When the key switch is turned to "ON", this blinking
function is deactivated. A flash then confirms the
system has switched to "ON".
The duration of the flash depends on the electronic
control unit program (see figure).
If the led turns off and remains so when switching
to "ON", it is necessary to check if there is battery
voltage in the electric control unit.
Connect the immobilizer tester to the diagnosis
socket (see ET4 125 manual) located below the
spark plug inspection port.
If the serial led remains off, check the control unitvoltage supply; in order to do this, disconnect the
control unit connector and check if:
- there is battery voltage between the terminal No.
6 (Red/Green) and the ground connection.
- there is battery voltage between the terminal No.
6 (Red/Green) and the terminal No. 9 (Negative)
as shown in the figure.
If no voltage is detected, check the wiring to the
battery positive lead and see if 15A fuse No. 4 is
in good conditions.
- there is battery voltage between the terminal No.
8 (Orange) and the terminal No. 9 (Negative) with
the key switch set to "ON" and the emergency
switch set to "RUN".
If no faults are found, replace the control unit; oth-
erwise check the wiring and the following compo-
nents:
- Engine stop remote control;
- Emergency cut-off switch;
- Key switch contacts.
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Virgin circuit
If the ignition system has not been programmed,
the engine can be started but it will run limited to
2000 rpm. When trying to accelerate, some evi-
dent loss of power may be felt.
Program the system with the MASTER (Brown)
and SERVICE (Black) keys as follows:
- Insert the MASTER key, turn it to "ON" and keep
it in that position for 2 seconds (limit values: 1 3
seconds).
- Alternately insert all the available black keys and
turn each one of them to "ON" for 2 seconds.
- Insert the MASTER key again and turn it to "ON"
for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 (Black) service keys can be pro-
grammed at one time.
Sequence and times must be strictly observed or
it will be necessary to repeat the procedure from
the start.
Once the control unit has been programmed, the
control unit is inseparably matched with the MAS-
TER key transponder.
This matching allows programming further service
keys in case of loss, replacement, etc. Each new
time new data is programmed the previously stor-
ed one is deleted.
If a service key setting is lost, it is essential to
carefully check the efficiency of the high voltage
system:
Shielded cap resistance ~ 5000 .
In any case it is advisable to use resistive spark
plugs.
Diagnostic codes
The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings.
That is, the led is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-second flashes.
After the failure code indication, a steadily on LED signals that ignition is disabled; see the table:
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2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial.
Ignition disabled-Vehicle immobilised
3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown trans-
ponder code. Ignition disabled-Vehicle immobilised
Diagnostic code - 2 flashes
Diagnosis code: 2-flashes
When the 2-flash code is detected, carry out the following checks:
- Check if the failure continues after changing key (MASTER key included). If the failure persists with
any key, disconnect the aerial connector from the control unit and check the aerial continuity with the020331Y multimeter.
If non-conforming values are measured, replace the aerial.
If no failures are found in the aerial, replace the control unit.
CAUTION
BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURECODE IS INDICATED. THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT
Electric characteristic
immobilizer aerial
~ 7 9 Ohm
Ignition circuit
Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a
spark in the spark plug.
The battery provides the basic power supply. The system is adjusted so that the start-up system im-
mediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition
system.
The Pick-Up is connected to the control unit by a single cable; then, for the ground circuit, the control
unit is connected to the Pick-Up by the chassis and the engine ground lead.
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To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis
ground connection bonding is efficient.
No spark plug
Once the lack of power to the spark plug has been
detected and the led indicates it can be ignited,
follow this procedure:
- Pick-Up check.
Disconnect the control unit connector and check
that the cable between terminal No. 11 (Green)
and terminal No. 9 (Black) is not interrupted.
Check the Pick-Up and its power line:
Electric characteristic
Pick-up resistance value
Pick-up resistance value: 105 124 Ohm
If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine
manual). If non-conforming values are detected, replace the Pick-Up, otherwise check the cable har-
ness and the connections. In case conforming values are measured and the wiring and connections
check is OK, try replacing the control unit (without programming) and make sure the failure has been
solved by checking sparks are produced in the spark plug; only then program the control unit. If no
sparks are produced with the new control unit, proceed as follows.
- HV primary coil check
Disconnect the control unit connector and check
that the cable between terminal No. 17 (Violet) and
terminal No. 9 (Black) is not interrupted (see fig-
ure). If non-conforming values are detected, dis-
connect the two connectors on the HV coil and
check its continuity (see figure). If the values are
correct, repair the cable harness and restore the
connections; otherwise, replace the HV coil.
Electric characteristic
High voltage coil primary resistance value
High voltage coil primary resistance value: 0.4
0.5 Ohm
HV coil secondary check
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Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable
terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace
the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.
Electric characteristic
High voltage coil secondary resistance value
High voltage coil secondary resistance value: ~ 3000 300 Ohm
- Pick-Up.
Disconnect the control unit connector and connect
the positive wire to connector No. 11 and the neg-
ative wire to connector No. 9 (see figure).
Use the start-up system to run the engine and
measure the voltage produced by the Pick-Up.
Replace Pick-Up if non-conforming values are
measured.
Electric characteristic
Pick-Up voltage value
Pick-Up voltage value: > 2 Volt
- H.V. coil
With the control unit and HV coil connected, meas-
ure the voltage of the coil primary during the start-
up test with the voltage peak adaptor and con-
necting the positive terminal to the earth one and
the negative to the coil positive connector.
If non-conforming values are measured, replace
the control unit.
N.B.
THE PLASTIC CAP OF THE POSITIVE TERMI-NAL ON THE HV COIL PRIMARY IS BLACKAND THE NEGATIVE TERMINAL ONE ISGREEN.
Electric characteristicHigh voltage coil voltage value
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High voltage coil voltage value: > 100 Volt
Battery recharge circuit
The recharge system is provided with a three phase alternator with permanent flywheel.
The alternator is directly connected to the voltage regulator.
In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety
fuse.
The three- phase generator provides good recharge power and at low revs a good compromise is
achieved between generated power and idle stability.
Stator check
Disconnect the connector from the voltage regulator and check there is continuity between any yellow
cable and the other two cables.
Electric characteristic
Ohm value:
0.7 0.9 Ohm
Also check that all yellow cables are insulated from
the ground connection.
If non-conforming values are detected, repeat thechecks directly to the stator. In case of further rep-
etitions of incorrect values replace the stator or
repair the wiring.
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- With a tester, check the circuit between connec-
tions 5-3 and 5-1 is not interrupted.
- Check the earth isolation on the three phases of
stators 5-earth, 3-earth, 1-earth.
Stage indicative resistance: 0.7 - 0.9
Minimum oil pressure switch check
- With a tester, check the circuit between connec-
tions 4 and ground (with engine off) is not inter-
rupted.
Pick-Up check
- Check that there is a resistance of about 105
124 at 20 C between connection 2 and ground.- In case of values different from the ones stated,
replace the defective parts.
N.B.
VALUES ARE STATED AT AMBIENT TEMPER-ATURE. A CHECK WITH THE STATOR AT OP-ERATING TEMPERATURE MAY RESULT INVALUES HIGHER THAN THOSE STATED.
Voltage regulator check
With a perfectly charged battery and lights off,
measure voltage at the battery poles with a high
running engine.
The voltage should not exceed 15.2 Volt.
In case higher voltages are detected, replace the
regulator.
In case of voltage values lower than 14 Volt, check
the stator and the corresponding cable harness.
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Recharge system voltage check
Connect an ammeter induction clamp to the volt-
age regulator positive terminal, measure the bat-
tery voltage and turning on the vehicles lights with
engine off, wait for the voltage to set at about 12
V. Start the engine and measure the current gen-
erated by the system with lights on and a high
running engine.
In case the generated current value is lower than
10A, repeat the test using a new regulator and/
stator alternatively.
Choke Inspection
Refer to the engine section to check the resistance
and operating conditions of the component. As re-
gards voltage supply, keep the connector connec-
ted to the system and check that the two terminals
receive battery voltage when the engine is on (see
figure).
If voltage is detected, replace the automatic starter
as it is surely failing.
If no voltage is detected, connect the multimeter
negative terminal to the earth terminal and the
positive terminal to the automatic starter orange
cable; with the key switch set to ON check
whether there is battery voltage; if there is no volt-
age, check the wiring connections to the key
switch and that the 15A fuse works properly.
If there is voltage, check again the ignition control
unit connector. After disconnecting the starter,
start up the engine and keep it at idle speed; then
check there is voltage connecting the multimeter
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positive probe to terminal No. 8 (Orange), and the
negative one to terminal No. 10 (Brown) (see fig-
ure).
Replace the control unit if there is no voltage; oth-
erwise, check the wiring connections between the
starter and the control unit.
Lights list
LIGHTBULBSTABLE
Specification Desc./Quantity
1 Low-beam bulb Type: HALOGEN (H1)
Power: 12V - 55WQuantity: 1
2 High-beam light bulb Type: HALOGEN (H1)Power: 12V - 55W
Quantity: 1
3 Helmet compartment light bulb Type: CYLINDRICPower: 12V - 5W
Quantity: 1
4 Rear turn indicator bulb Type: ALL GLASSPower: 12V - 5W
Quantity: 2 RHS + 2 LHS
5 Rear tail light bulb Type: ALL GLASSPower: 12V - 5W
Quantity: 1 RHS + 1 LHS
6 Stop light bulb Type: SPHERICALPower: 12V - 10W
Quantity: 2
7 License plate light bulb Type: ALL GLASSPower: 12V - 5W
Quantity: 1
8 Front turn indicator bulb Type: ALL GLASSPower: 12V - 10W
Quantity: 1 RHS + 1 LHS
9 Front tail light bulb Type: ALL GLASSPower: 12V - 3W
Quantity: 1 RHS + 1 LHS10 Instrument panel bulb Type: ALL GLASS
Power: 12V - 2WQuantity: 4
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Fuses
The electrical system has eleven fuses divided into
two fuse boxes to protect the different installation
circuits. One of them is inside the battery compart-
ment and the other is at the right internal side of
the footrest. To be able to reach them, loosen the
screw "A" and remove the plastic cover. The chart
shows the position and characteristics of the fuses
in the vehicle.
CAUTION
BEFORE REPLACING THE BLOWN FUSE,FIND AND SOLVE THE FAILURE THATCAUSED IT TO BLOW. NEVER TRY TO RE-PLACE THE FUSE WITH ANY OTHER MATERI-AL (E.G., A PIECE OF ELECTRIC WIRE).
FUSECHART
Specification Desc./Quantity
1 Fuse No. 1 Capacity: 10AProtected circuits:
from the battery: headlight remote controlLocation:battery compartment
2 Fuse No. 2 Capacity: 7.5 AProtected circuits:
from the battery: saddle opening receiver,hazard and turn indicator control device, anti-theft device pre-installation, instrument pan-
el, helmet compartment lightingLocation:battery compartment
3 Fuse No. 3 Capacity: 15 AProtected circuits:
live: parking control ECU, fuses 8, 9 and 10Location:battery compartment
4 Fuse No. 4 Capacity: 15 AProtected circuits:
from the battery: voltage regulator, electricfan, electronic ignition device
live: engine stop switch, starter, electronic ig-nition device, TPS, fuses 7 and 11
Location:battery compartment5 Fuse No. 5 Capacity: 20AProtected circuits:
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Specification Desc./Quantity
from the battery: parking control ECULocation:battery compartment
6 Fuse No. 6 Capacity: 4AProtected circuits:start-up, stop lights.
Location:footrest7 Fuse No. 7 Capacity: 4A
Protected circuits:panel lighting, tail lights,license plate lightLocation:footrest
8 Fuse No. 8 Capacity: 7.5 AProtected circuits:lights switch, horn, wiring
for Tom-TomLocation:footrest
9 Fuse No. 9 Capacity: 7.5 AProtected circuits:saddle opening receiver,hazard and turn indicator control device, anti-
theft device pre-installation, turn indicatorswitch, instrument panel, horn remote control
Location:footrest
10 Fuse No. 10 Capacity: 7.5 AProtected circuits:headlight remote control
Location:footrest
11 Fuse No. 11 Capacity: 3AProtected circuits:electric pump control de-
viceLocation:footrest
Dashboard
A = Led immobilizer / anti-theft device
B= Speedometer with twin scale (km/h and mph)
C = CLOCK switch
D = Digital display
E = Front suspension locking system warning light
(if available)
F = SET switch
G = Rpm indicatorH = Fuel gauge
I = Warning light for helmet compartment courtesy
light on
L = Engine control telltale light and injection sys-
tem failure warning light
M = Low fuel warning light
N = Engine stop warning light
D= Turn indicator warning light
P = Low oil pressure warning light
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Q = Front suspension locking system failure warn-
ing light (if available)
R = Warning light for parking brake engaged
C = High-beam warning light
Pushing the CLOCK button for less than 1 second displays the following sequence:
TIME
DATE
To set the clock push and hold the CLOCK button longer than 3 seconds.
The numbers showing the hours will begin flashing.
Set the hour using the SET button. Push the CLOCK button again and the minutes numbers start
flashing.
Set the minutes using the SETbutton. Push the CLOCK button again and the day numbers startflashing.
Set the day with the SET button. Push the CLOCK button again and the month numbers start
flashing.
Set the month with the SET button. Push the CLOCK button again and the year numbers start
flashing.
Set the year with the SET button. Press the CLOCK button again for 4 seconds to exit the ad-
justment menu.
During the reset pr